Epoxy Floor - Concrete Floor Paint - Garage Flooring

1. PAINT     Back to Home Page

The U.S. paint and coating industry primarily includes manufacturers of architectural coatings (i.e., house paint) a diverse collection of product coatings applied as part of the manufacturing process (original equipment manufacturer, or OEM), and special purpose coatings, such as those for garage floor coatings, marine applications, offshore oil and gas rigs, auto refinish and highway and traffic markings. Raw materials suppliers and distributors are also components of the industry.

Generally, paints and coatings are applied to products to protect them from environmental effects, and improve their consumer appeal. In some cases, paints and coatings provide an element essential to a product's use, such as the coatings that protect food and beverages in metal cans from contamination and spoilage.

The chemistry of paint is a continuously developing science and although the ingredients have changed over the years, the four basic types of materials that make up paint are, Solvents,
Binder, Pigment and Additives.

Solvent

Solvent is the liquid or vehicle that carries the solid components of paint. It must be present to allow the paint to be of correct consistency for application by brush, roller, spray or dipping. It also promotes the transportation of resins into substrates. A good example is solvent based concrete floor coatings. The resins are actually conveyed into the substrate by the vehicle (solvent).

The choice of solvent also effect the flow of the paint after it has been applied so that the film develops the correct surface appearance and so that the paint film "wets" the substrate to which it has been applied thus maximizing adhesion to the substrate. The choice of solvent also influences the initial drying properties of the paint film.

The binder, or resin component is either dissolved in liquid solvent or dispersed in non-solvent. After application the solvent evaporates to leave a solid dry film on the substrate.

The most common solvents used in floor paint and coatings are water or mineral turps, water is used in acrylic floor paints and mineral turps is used in so called "solvent based paints" such as alkyd based floor coatings. A wider range of solvents are used in industrial type floor paints and coating, these are generally stronger solvents and include aromatic hydrocarbons, ketones and esters.

Binder

The binder or resin is one of the most important components of floor paint. It is the basic solid film former that remains after the solvent has evaporated and which binds the pigment particles together into a cohesive paint film.

The binder determines many of the necessary film properties such as adhesion, gloss level, hardness, abrasion resistance, flexibility, speed of drying and durability. In heavy-duty solvent based concrete coatings and paints the binder is usually an alkyd resin, in water based floor and concrete coatings the binder is usually an acrylic emulsion but some vinyl emulsions are also used.

A wider range of binders are used in industrial floor paints, these are usually very specialized and specific to the type of paint in which they are used. Industrial floor coatings vary, from simple alkyd based floor coatings for general use, to paints for manufacturing and industrial floor coatings applications.

The more specialized binders include polyurethane resins, epoxy resins, silicone based resins, acrylic resins and inorganic silicate based resins.

Pigment 

This is the component that gives floor paint and coatings the critically important properties of color and opacity. The pigments used in floor paints are normally present as fine solid particles that are dispersed, but not soluble, in the binder and solvent.

The most common pigment used in floor paint and coatings is titanium dioxide and the majority of white paints use this pigment. Other inorganic colored pigments are used such as red and yellow iron oxides, aluminum flakes and mica flakes.

Synthetic organic pigments are used to produce very bright clean colors such as blues, greens, reds, oranges and violets. Extender pigments are used in primers and primer surfacers to enhance film properties and to determine the filling and sanding properties of the concrete floor coating film. They are also used in penetrating sealers and the like where the use of more expensive colored pigment is not necessary. 

The most common extender pigments are barium sulphate, china clay, talc and various other silica based pigments.

Additives

Additives are the specialist components of paint, they are used in small quantities to improve production and storage properties of the liquid concrete floor coating as well as application and other performance properties of the floor paint film.

Some typical additives that are used are,

Wetting/Dispersing agents, used to facilitate wetting of the pigment particles and dispersion of coarse aggregated pigment particles to the degree of fineness required.

Anti-settling agents, used to reduce settling of pigment particles during storage.

Anti-skinning agents, used to prevent the formation of a tough skin film on the floor coating during storage.

Drying/Curing agents, used to improve and control the drying properties of the paint film.

Stabilizers, used to improve long term storage properties of the liquid paint.

Anti-foaming agents, used to prevent foaming or bubbling of floor coatings during manufacture and application.

Anti-marring agents, these are usually silicone based compounds that are used to improve resistance to scratching and marring of the paint film.

Anti-mould agents, used to reduce mould growth on the floor paint film in very damp and humid environments.

Three common types of paint are:

Solvent-based (Oil or Alkyd) In oil-based floor paint the liquid solvent is typically mineral spirits. Oil-based paint dries slower than latex — usually taking 24 hours to dry.

Water-based (latex or acrylic) The liquid is water. An advantage to latex paint is that it dries relatively fast, which may or may not be desirable in hot weather or direct sunshine. Clean up is faster, requiring only soap and water.

Primer (solvent or water-based) Primers allow floor paint and coatings to bond better, inhibit rust, improve performance and increase the film life expectancy. The right primers can help cover imperfections improving the overall appearance of the finish because typically, especially when they are high build sandable floor coating primers. When you select a floor coating primer, make sure you consider your application carefully before making your selection because often garage floor coatings, concrete coatings, wooden deck paint, metal and masonry require separate primers.

Sheen is the term used to describe the degree of light reflection a paint or coating has. Usually the less sheen a paint has, the less stain-resistant it is. Different manufacturers may have various trade names for them, but in general sheens are classified as:

Gloss is the toughest. Virtually all floor coatings, industrial and marine coatings are high gloss. It cleans easily and resists scuffs better. Therefore, it's a good choice for areas of high traffic or constant use, like garage floor coating or industrial floor coating applications. High gloss concrete floor paint provides a sleek, eye-catching look. Gloss floor paint will, however, show imperfections in the surface more than other sheens.

Semi-gloss floor coatings are also durable and easy to clean, but have less shine than gloss. They are about as suitable for use in floor and concrete coating applications in most instances.

Satin (sometimes referred to as eggshell or low luster) offers a good combination of easy-clean and moderate sheen. It's a good choice for walls and trim but higher gloss performs better in most instances.

Flat or low luster floor paint and coatings are usually found in porch and deck paint products. It hides imperfections well and spatters less when applied. It's also easier to touch up, however, it tends to show mar easily.

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2. CONCRETE PAINT

Painting concrete is normally only considered when it is required to cover an existing slab or wall. For instance, after a crack has been repaired. For exterior areas that receive heavy foot or motorized traffic it is likely the concrete paint may wear away unless a high quality epoxy product is used.

Fresh concrete should never be painted. Allow the concrete to cure for at least 28 days-follow the paint manufacturer recommendations. Do not apply curing compounds to concrete which will be painted because these inhibit adhesion of concrete paints ad coatings.

Concrete walls should typically be the type that breathes so any moisture that comes up through the concrete can vaporize and is not trapped beneath the surface which could cause the paint to blister. The exception would be waterproof concrete paint such as Top Secret Coatings 1- Part Epoxy (TS-100) or Hard-Shell Urethane (TS-2) which are often applied to prevent the movement of moisture through the slab.

An option for consideration is an alternative to concrete paints are concrete sealers such as Seal-it! Penetrating Sealer (TS-104). This product provides improved resistance to weather, water, stains, and abrasives. Seal-It! also offers resistance to rain, sun, freezing temperatures, petroleum, and deicing salts. Concrete sealers make clean up easier than untreated concrete but do not improve traction or add color to concrete surfaces.

1- Part Epoxy is a remarkable concrete paint because it is catalyzed by oxygen rather than chemically making it the latest in coatings technology. It is far easier to use because it is not chemically catalyzed and produces a non-toxic film. This product out performs traditional two part epoxy in most categories.

1-Part Epoxy creates a high-gloss waterproof film that remains both hard and flexible at the same time! It adheres to almost any surface, seals, waterproofs and is resistant to chemicals, spilled fuel and acids. It is impact resistant to 500 PSI, heat resistant to 350 + degrees, color-fast, UV resistant, non-chalking and it resists cracking, chipping and peeling. Additionally, it covers three times the area of typical paint because its maximum dry film thickness is only two mils which is exceptional.

Before concrete can be painted, dirt, oil, and efflorescence must be removed form the concrete.

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3. GARAGE FLOOR PAINT

Garage floor paints and concrete coatings have become very popular in recent years creating significant demand for them. Unfortunately, garage floor paint quality varies greatly from manufacturer to manufacturer so results are often mixed. Moreover, cheap, low quality imports from China (see Epoxy-Coat and Armor-Poxy) lower consumer confidence giving the industry a black-eye. This is unfortunate because Top Secret Coatings strives to produce only the highest quality garage floor paint and floor coatings. Manufacturers that produce or import low quality garage floor paint and products typically create dissatisfied customers.

Solvent based epoxy garage floor paints and coatings can be expensive but they are worth the extra expense in many applications especially in aircraft hangar floor coating, industrial floor coating and high traffic applications. To a large degree you ‘get what you pay for' when it comes to garage floor paint.

A common non-solvent thinner is a chemical known as nonyl phenol. This chemical is sometimes used in small amounts to make 100% solids epoxy floor paint, however, cheap epoxies may contain large amounts of this inexpensive chemical. You will want to check your epoxy MSDS for references to nonyl phenol. Top Secret epoxy paints do not include this inexpensive ingredient.

Another clue of cheap and imported epoxy include ‘induction time' (after mixing the two components the mixture must sit for several minutes to ‘self cook' before being applied), and crystallization of either part A or part B if left sitting for several months (like crystallized honey, simple heating will dissolve the crystals). After the two epoxy parts have been combined there is a working time (pot life) during which the epoxy can be applied or used. Generally the pot life will be anywhere from minutes to one hour or longer. At the end of the pot life the mixture becomes very warm or even hot as it begins to harden. This harsh chemical reaction is one of the reasons traditional two part epoxy garage floor coatings may chalk and discolor.

1-Part Epoxy (TS-100) is remarkable because it is catalyzed by oxygen rather than chemically making it the latest in coatings technology. It is far easier to use because it is not chemically catalyzed. There is no induction time and no nonyl phenol used. This high grade garage floor coating product out performs traditional 100% solids epoxy and water-based epoxy in every significant performance category.  

1-Part Epoxy creates a high-gloss waterproof film that remains both hard and flexible at the same time! It adheres to almost any garage floor surface, it seals, waterproofs and is resistant to chemicals, spilled fuel and acids. It is impact resistant to 500 PSI, heat resistant to 350 + degrees, color-fast, UV resistant, non-chalking and it resists cracking, chipping and peeling. Additionally, it covers three times the area of typical garage floor paint because its maximum dry film thickness is only two mils which is exceptional.

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4. FLOOR COATINGS IN MARINE ENVIRONMENTS

While we typically think of marine paint as what goes on a ship, pleasure craft or barge a large share of marine paint and coatings protects infrastructure and floors in marine environments as well. Marine paint and coatings protect and beautify infrastructure in marine areas as well as improving safety for those who manage Marine and Coastal sites. Non Skid floor coating products add safety and confidence in marine areas.

Top Secret non skid and industrial floor coatings are a great choice to fulfill these needs as they provide excellent protection and corrosion resistance, are environmentally friendly, exhibit low-odor, provide the ability for brilliant color and are easy to apply. Typical acceptable substrates for our non skid floor coatings include: steel, galvanized steel, aluminum, concrete or masonry, and wood.

Although not typically suggested first, waterborne acrylic non skid floor coatings (see Floor-Grip) have been successfully utilized for over twenty years in these environments and are suitable for decks, docks, buildings, bridges spanning inter-coastal waterways, as well as light houses. This product has also been successfully used on ship interiors, as well as exteriors of stationary vessels. Some notable locations where water-borne marine paint has been applied include The Hunting Island Historic Lighthouse, the Battleship New Jersey and the Neuse River Bridge.

Preparation is the most important part of any painting project. First you will want to Repair all damage, scratches, voids and cracks. Once that has been accomplished sand or scuff the entire surface to improve adhesion. Then you will want to pre-clean in preparation for marine paint or primer.  We recommend using TS-695 Etching Cleaner prior to the application of any concrete floor coating system.

Primer is always required on aluminum and fiberglass surfaces. In most instances the recommended primer will Etching Primer (TS-664). Concrete Floor Paint applications require Ever-Last Epoxy Primer (TS-6433). 1-Part Epoxy and Urethane Reinforced Alkyd (TS-4) are exceptions. This is an excellent, government spec, high-build epoxy primer that is a barrier coating. Once the epoxy primer has been applied and allowed to dry 12-24 hours it is ready for the top coat. Our non skid floor coatings that include the aggregate are typically applied directly to concrete or wood without primer.

Apply the top coat using a brush, non shedding roller cover or spray. Up to two or three thin coats are acceptable as desired. For best results you should recoat within 24-48 hours other wise sanding is typically required. There is no need to sand between applications when applied within 48 hours. The top coat should be fully cured before repairing any runs, sags or blemishes. Allow top coat film to cure thoroughly before entering full service duty.

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5. DECK PAINT

Old peeling, cracked or chalked deck paint can give you the blahs! Why not give your deck a colorful coat of deck paint or stain? Sometimes we're so busy decorating the inside of our homes that we neglect the outside and a porch, patio, or deck is often last on the list. A spruced-up outdoor area, however, will give you additional living space for family fun and entertainment.

Today, more money is being spent on decks than ever before and deck paint, sealers, deck stains and clear coats are an important part of this. Even so, many people are unhappy with the results because results are too often short lived. Reasons vary but inferior products, poor preparation and application mistakes are all contributors.

Contrary to advertising claims, decks, whether they are made of concrete, wood, composite or plastic must be maintained and protected. Thus, millions of gallons of sealers, deck paint, deck stain and cleaners are sold annually to protect and keep them looking new. Before beginning, you need to know about the two types of deck sealers: topical and penetrating.

The most common topical deck sealer is acrylic, which forms a film over the surface. It attaches itself to the concrete by mechanical bond, much like paint. Such deck sealers can be applied to new or old concrete and most tile applications by spraying or rolling them onto the surface. To determine if a specific surface can receive a sealer, a simple water test can be conducted. If the surface won't allow water to be absorbed, the sealer cannot penetrate or adhere to it. Topical sealers have not been widely used on pool decks because they became slick when wet.

Today's (Top Secret Coatings) technology has solved this problem. Non-slip floor coatings that are aggregate added increase safety are durable, long lasting and beautiful in appearance. Top Secret Coatings offers a variety of non slip floor coatings and deck paints. Decorative concrete decks are becoming increasingly popular and must be sealed to last. We offer a number of sealers, deck paints, non slip paints and coatings that work well for this type of surface.

Seal-It! Penetrating Sealer is often the sealer of choice. Acrylic sealers are transparent and can give the concrete a "wet look" or sheen but often do not last for long. Sealer-It seals permanently in just one application making it a favorite. 1-Part Epoxy Clear, 1-Part Epoxy colors and Deck-Pro deck paints are longer lasting, more durable, more versatile than home center brands and can be applied to porous and non-porous surfaces unlike common acrylic sealers.

In addition to enhancing the look of the deck and protecting it from the weather, topical sealers, clears, deck stain and deck paint reduce staining. Liquids such as wines, sodas, juices and sports drinks can be easily wiped up without staining the surface. The deck also is shielded from fallen leaf stains, furniture rust and other items that can be spilled or dropped on it.

A good deck paint such as Deck-Pro functions as an anti-spalling agent, too. In climates that experience freeze-thaw cycles concrete surfaces should be treated with a waterproof barrier concrete coating such as the Super-Fleck Floor Coating system or 1-Part Epoxy. These systems do not allow water to penetrate the concrete, so the liquid cannot freeze and expand below the surface. If it did, it would cause the top layer of concrete to pop off and ruin the finished surface.

1-Part Epoxy does not just form a film over the surface. Instead, the solvents drive the resins into the concrete pores creating a nearly unbreakable bond. Through a chemical reaction, it can seal the pores actually becoming part of the concrete matrix.  Penetrating sealers such as Seal-It! do not change the appearance of the surface. Deck paints, deck stains, clears or sealers can be used on concrete, pavers, stucco, stone, brick and tile and can be applied by spraying, rolling or brushing.

Besides acting as spall-resistant systems, 1-Part Epoxy, 1-Part Epoxy Clear and Seal-It! also prevent effervescence on concrete surfaces. Our penetrating sealer is commonly applied to natural stone water features to help stop water loss and the bleeding of the stone but when color is desired or more durability is required one of the former products is the preferred choice. 

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6. EPOXY FLOOR PAINT

Epoxy floor paint can be expensive but it is worth the extra expense in many applications such as garage floor paint or high traffic or industrial area applications. To a large degree you ‘get what you pay for' when it comes to epoxy paint. A common non-solvent thinner is a chemical known as nonyl phenol. This chemical is sometimes used in small amounts to make epoxy paint, however, cheap epoxy floor paints may contain large amounts of this inexpensive chemical. You will want to check your epoxy MSDS for references to nonyl phenol. Top Secret epoxy floor paints do not include this less expensive ingredient.

There are only a handful of different epoxy bases, a handful or two of hardening agents, and a handful of solvents, fillers, and solvent-free extenders used to formulate epoxy floor paint products. Epoxy is not cheap to manufacture so it is a safe bet that $25, $35, $45 epoxy floor coatings represent the low end of the product line where price is the only purchasing criteria.

Another clue of cheap epoxy floor paint includes ‘induction time' (after mixing the two components the mixture must sit for several minutes to ‘self cook' before being applied), and crystallization of either part A or part B if left sitting for several months (like crystallized honey, simple heating will dissolve the crystals).

After the two epoxy parts have been combined there is a working time (pot life) during which the epoxy can be applied or used. Generally the pot life will be anywhere from minutes to one hour or longer. At the end of the pot life the mixture becomes very warm or even hot as it begins to harden. This harsh chemical reaction is one of the reasons traditional two part epoxy floor coatings chalk and discolor.

1-Part Epoxy is remarkable because it is catalyzed by oxygen rather than chemically making it the latest in coatings technology. It is a one of a kind resin blend that blend that out performs traditional two part epoxy in every significant performance category. It creates a high-gloss waterproof film that remains both hard and flexible at the same time! It adheres to almost any surface, seals, waterproofs and is resistant to chemicals, spilled fuel and acids. It is impact resistant to 500 PSI, heat resistant to 350 + degrees, color-fast, UV resistant, non-chalking and it resists cracking, chipping and peeling. Additionally, it covers three times the area of typical epoxy floor paint because its maximum dry film thickness is only two mils which is exceptional.

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7. GROWTH POTENTIAL IN CONCRETE FLOOR COATING INDUSTRY

The potential for growth in the concrete floor coatings industry is startling. When one considers that less than 1% of garage floors are currently coated and so much consumer interest in garage floor coating and remodeling is evident it is no wonder explosive growth is currently being seen by many contractors. One industry insider predicts that this segment of the paint and coating industry has the greatest room for growth than any other industry sector. 

Big innovative ideas in the concrete floor coatings industry often come in small packages. One of the hottest products on the market today is our Super Floor D-I-Y kit. This system is such a hit that the original 12 colors have been expanded recently to include 100 base colors. Combine that with the scores of Super-Fleck chip color options and you can create a customized concrete floor coating that reflects your own personality and preferences.  Top Secret’s Heavy-Duty product, Super-Fleck Concrete Floor Coating System leads the way since it is so inexpensive, durable and available in so many color choices.

"The response was so incredible. It's far outweighed our expectations," said Peter Harrett, Top Secret Coatings sales manager. "There are so many inferior products on the market, and at higher prices we couldn’t miss with this one."

Thus far, Top Secret Coatings enjoys a first-to-market advantage in innovative concrete floor paint for garage floors. An even bigger hit for Top Secret Coatings has been its garage floor paint called 1-Part Epoxy which has been an overnight success, with significant potential growth given that only 1% of garages are painted.

Contractors can enhance the appearance of a high-traffic floor with the Super Floor (Super Fleck) Floor Kits from Top secret Coatings. These decorative concrete floor coating systems can be used for offices, shops, garages, restaurants or other interior or exterior surfaces. In fact, they are tough enough for manufacturing, commercial, retail, even areas subject to heavy motorized traffic.

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8. CHOOSING & APPLYING FLOOR PAINT & COATINGS

Not all floor paint and coatings are created equal and today choices abound. You can choose between water based and solvent based floor paint products, however, solvent based products dominate the market. The water based epoxy and acrylics are newer technologies, however, in general terms they are always inferior to solvent based floor paint systems such as those offered by Top Secret Coatings. Tests have shown that they are durable and VOC levels are often far less giving them the edge in many markets.

We at Top Secret Coatings only recommend solvent based floor paint and coating products, however, there are certain applications where water based products may be preferable. These are the products that are used in institutions where strict air quality standards or health concerns allow only the lowest odor products to be applied. These often include kitchens, nursing homes and hospitals. When considering water based floor paint and clear products for these applications we recommend Aquathane (TS-6990) or Crystal-Clear (TS-166) floor finishes. This level of product quality is not typically available at home centers or paint stores but they are available from us on our website at www.topsecretcoatings.com.

Here’s a hint: When you buy floor paint at a home center or paint store the clerk will shake the can before sending you home with it. This mixes up the pigments in the paint so that the final finish is uniform. That part is good but shaking cans immediately before use can be a mistake because shaking injects lots of air into the resin. These tiny air bubbles don't always go away before you apply the finish or before it dries leaving permanent bubbles in the finish. We recommend stirring the product with a paint stick instead of shaking. The proper way to stir is not to go round and round like you might stir coffee. For best results you will want to pull the stick from the side of the can towards the middle while lifting the stick up. The lifting action pulls up thicker components from the bottom of the can and brings them back into suspension. If you mix your product like this for about one minute and you will get good results.

When applying urethane or epoxy floor paint or coatings we recommend non-shedding lambs wool applicators or mohair rollers. This is what professional garage floor coating and hardwood floor finish contractor’s use. Either applicator is available from Top Secret Coatings and most paint stores and home centers. You will want to brush the edges and roll or use the lambs wool applicator in the larger areas. The lambs wool applicator is only intended to apply urethane to wide open spaces. You also need to work fast, especially if it is warm and there is significant air movement. Failure to keep a wet edge will show up as streaks and lap marks. It is helpful to have someone do all of the brush work in front of the applicator while one person progresses across the floor non-stop with the applicator.

Subsequent floor coating reapplications must be made within 48 hours or sanding will be required. Vacuum up the dust before you do each coat. Before applying the next coat you will want to wipe the surface down with a rag saturated in paint thinner or mineral spirits to remove every trace of dust.

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9. EPOXY

Top Secret Coatings is known for producing high quality, new generation epoxy and modified epoxy blended resin epoxy floor coatings. For your information, one of the hardest finish paints you can buy is an epoxy and Top Secret offers more varieties of epoxy than any other coatings manufacturer. Our feature product, 1-Part Epoxy (TS-100) is an excellent example. Modified alkyd floor paints are also exceptional so it would be good to consider TS-4 Urethane Reinforced Alkyd as a value option.

Perhaps you have used an epoxy to mend a broken dish or some other object. There are a wide variety of epoxies on the market for an even larger variety of application possibilities including garage floors, basement floors and walls, concrete structures, equipment, tools, motorized vehicles, roofs even furniture.

Some epoxy coatings are actually stronger than concrete when properly applied. It is similar to the welding process with metal. An excellent example is the outstanding strength of Ever-Last Epoxy (TS-6433). While this product is available online it is seldom available in local paint stores and home centers. It is typically sold at specialty supply houses or online at www.topsecretcoatings.com.

1 Part Epoxy is remarkable because it is catalyzed by oxygen rather than chemically making it the latest in coatings technology. It is a one of a kind blend of four resins. This product out performs traditional two part epoxies in most categories. It creates a high-gloss waterproof film that remains both hard and flexible at the same time! It adheres to almost anything, inhibits rust, waterproofs and is resistant to chemicals, spilled fuel and acids. It is impact resistant to 500 PSI, heat resistant to 350 + degrees, color-fast, UV resistant, non-chalking and it resists cracking, chipping and peeling. Additionally, it covers three times the area of typical paint because its maximum dry film thickness is only two mils which is exceptional.

1-Part Epoxy is very economical to use because it covers 600-800 square feet per gallon on sealed surfaces depending on the method of application. Usually only one coat is required. Top Secret’s lead-free formula meets or exceeds many DOD MIL-SPECS and all general EPA, USDA and FDA standards and it is available in a wide range of popular colors.

It provides outstanding adhesion to Metal, Wood, Concrete, Masonry, Ceramic Tile, Asphalt, Vinyl and Fiberglass surfaces. It is easy to use because it can be brushed, rolled or sprayed and it cleans up with mineral spirits. This lead-free formula is low VOC, is engineered to provide extraordinary performance, durability, and is non-toxic when dry so it is safe around children and animals.

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10. INDUSTRIAL FLOOR COATINGS

After architectural paint, Industrial paint and coatings is the second most major significant segment of the paint industry by volume. This portion of the industry supplies products for application to a broad range of manufactured goods such as furniture, appliances, aircraft, boats and ships, machinery and farm equipment. The industrial paint and coatings industry provides many Americans with employment since industrial paint is typically produced domestically not imported.

When it comes to coating industrial areas, no two jobs are alike. But there is one sure thing; a quality industrial floor coating job should begin with a quality product. Whether you're an industrial floor coating contractor, engineer, facilities manager, architect or a floor coatings specifier we hope you come to rely on Top Secret Coatings for information, education, support and quality products. We want to be your resource guide whether you're coating concrete or steel for corrosion control and industrial maintenance or, applying protective coatings on concrete, masonry, or metal.

One of the most important aspects of any industrial floor coating job, whether it be the painting of wood trim on a house or a steel I-beam of a bridge, is proper surface preparation. Even the best quality paint will fail over an improperly prepared surface.

It is good to emphasize the importance of proper preparation of the surfaces to be painted in industrial floor coating applications. Any surface that is coated or painted should have a clean interface between the surface and the applied coating. This is very important in order to realize the full performance potential of the floor coating system. Contaminants (e.g., dirt, oil, mildew, salts, etc) at the interface can interfere with both the adhesion and barrier properties of the coating, and lower the overall performance.

While 100% epoxy industrial floor coating systems require extensive and very careful prep-work including scarifying, sanding, blasting and moisture testing Top Secret industrial floor coating systems typically only require cleaning with an etching cleaner (see TS-695 Etching Cleaner).

In industrial floor coating, the types of surfaces treated range from steel and concrete, to diverse substrates such as plastic, galvanized steel, aluminum, wood, cinder block walls, and even road surfaces. Of course, when coating previously painted surfaces, one must also consider the variety of weathered paints which could be encountered, such as epoxies, urethanes, acrylics, alkyds, and others.

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11. GARAGE FLOOR COATINGS

What is the first room you see when you come home from a hard day at work? Think about it; this is sort of a trick question. It's not the kitchen or the family room, it’s the garage! It is a room, and probably the least talked-about room when it comes to decorating. Most of us park our cars in the garage and enter the house without a second thought. Why not set the tone for your return to your castle with a spiffed up looking garage?

It's easy to add a coat of paint to the walls, maybe a tool organizer and a few shelves to control the clutter but the floor is a different story.  It may have taken some abuse over the years and may have been ignored. Have you considered a garage floor coating?

Most people are concerned about painting a garage floor because they think the paint won't last and will lift from the car parking on it so they don’t do anything about it. Hot-tire pick up is the culprit. Hot-tire pick up is when you drive a car onto the garage floor and the tires are extremely hot. The tire can pick up the paint and ruin the finish. People don’t realize it but tiers are made of many of the very same compounds paint is made of so the bond between a hot tire and paint can be a strong one.

We have good news for you because those days or over! Top Secret Coatings has formulated several garage floor coating systems that are resistant to hot tire pick up. Even with this; there are occasional application failures, but not because there was something lacking in the product but because of poor preparation prior to the garage floor coatings application. We always say “preparation is everything” so here are a few application tips we can share with you:

Begin by sweeping first. Then remove heavy oil and grease with TSP or similar detergent. Remember that all cleaners must be thoroughly rinsed with a power washer after cleaning because they can inhibit the bond if not properly removed before garage floor coatings are applied.

The next step would be to clean with an etching cleaner prior to applying a garage floor coating. We recommend TS-695 Etching Cleaner. Wet the floor first then flood it with the mixture and allow approximately five to ten minutes contact time. Scrub with a stiff broom or brush and then rinse. Repeat if necessary. Safety comes first so always wear protective glasses, and rubber gloves, when working with Etching Cleaner.

Concrete requires a thoroughly dry surface. Moisture will inhibit adhesion so be sure your floor is dry before moving floor with your garage floor coating application! You can test to see if your floor is dry enough, by placing the rubber car mat from your car on the floor, and allowing it to stand overnight. If the area under the mat is visibly darkened, or condensation has formed under the mat, you should allow for additional dry time.

The final step is the painting. Every Top Secret Coating order includes complete application instructions so once you have properly prepared your floor the actual painting is fairly straight forward.

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12. CEMENT PAINT

If you are considering cement paint for exterior walls or foundations the first thing you need to do is clean the foundation, wall or surfaces you plan to apply cement paint to. This is one of the few instances where we advocate the use of a pressure washer. Often rainfall causes dirt and silt to splash up onto a foundation so if you live in an area with clay soil, very fine clay silts can get deeply embedded in the pores of both the poured concrete and especially the concrete block. Pressure washers quickly and efficiently remove this silt prior to an application of cement paint.

Squirting the dirty masonry or cement with a regular garden hose and a nozzle will not remove all of the dirt. A stiff scrub brush with soap will work, but this involves a considerable amount of work. Once you have completed your cleaning rinse with clear water making sure they are perfectly clean before you move forward.

Motor and hydraulic oils can really cause a mess on concrete, brick and blacktop but the good news is that you can achieve excellent clean up results if you act quickly. Concrete is a dense surface but water and many other liquids can and do soak into the surface. While fresh oil stains can be easy to remove older oil stains garage may be a far greater challenge.

Removing fresh oil and grease stains will require a regular scrub brush, some liquid dish soap and water. Be sure to wet down the surrounding concrete to prevent quick drying. Once wet, all you need to do is squirt some liquid soap onto the stain then add water. This will prevent oil released during the cleaning process from causing a secondary stain. Scrub the stain vigorously and add enough water to make a rich lather of soap. The soap will emulsify the oil lifting it out of the concrete.

We do not recommend using a wire brush to scrub concrete surfaces because that can erode and scratch the concrete finish permanently marring the surface.  Many have successfully removed fresh oil stains from concrete driveways using a standard nylon bristle scrub brush purchased from local retailers. Some stains require several scrubbing attempts to completely remove all of the oil.

You can use the same method to attack the older stains in your garage floor or driveway. If the concrete finish on the garage floor is smooth, you may have a great chance of success. Smoothly troweled concrete is highly resistant to oil stains. This type of finish is generally unsuitable for exterior concrete because it slipperier when wet. Rough concrete finishes absorb oil faster than smooth troweled concrete surfaces.

If the old stain does not respond to the soap and water method you can consider using an etching cleaner such as TS-695 Etching Cleaner or even a solvent such as kerosene to help lift the stain. We do not recommend solvents for environmental reasons and because they can be more dangerous to work with. The fumes from solvents can ignite and cause serious damage to your person ort home. If you decide to use a solvent, you would only want to do so after consulting with your local fire department's fire prevention officer.

Some people have had success lifting oil stains using muratic acid. But keep in mind that muratic acid is sulfuric acid and can be very dangerous to work with. It is a seriously caustic chemical. Even when mixed one part acid to ten parts water it can dissolve some of the cement paste at the surface. Couple this with scrubbing and you can adversely alter the appearance of the concrete. For these reasons we recommend TS-695 Rynolite Etching Cleaner for use on stubborn cement stains.

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13. INDUSTRIAL FLOOR PAINT

It is not only possible to paint industrial and manufacturing floors satisfactorily, but with today’s new generation industrial floor paint products, your job may actually end up exceeding your expectations. There is no magic in successfully painting an industrial or commercial floor. Simply follow a few simple steps and use the right products to achieve attractive, durable, long-lasting results.

Just about any flooring surface that is in good shape can be painted. Concrete, wood, ceramic tile, vinyl, masonry, tile, etc. can all be painted with relative ease. The only surfaces that may present a problem would be previously painted or older below grade floors that could have hydrostatic pressure, or those in contact with a very wet soil.

Water that seeps into concrete can sometimes cause a painted finish to peel, if not properly applied or inferior products have been used. Many modern concrete floors installed since the 1970's have a vapor barrier under the slab preventing moisture or water vapor out allowing the paint to adhere or bond properly to the concrete. Top Secret Coatings offers a variety of quality industrial quality and commercial floor paint products that the D-I-Y’er can easily apply at home.

Most people take for granted the hardness and durability of clear urethanes. Quality with products such as Hard-Shell Urethane (TS-2) or Aquathane (TS-6990) have been formulated for use in industrial applications and professional sports arenas so they are more than acceptable for at home use. For example, customers using these Top secret products on hardwood floors are achieving excellent results with these products. Home center brands can begin to look dingy and dull in a very short amount of time.

Thin coats of smooth Aquathane can protect hardwood floors from dirt and other contaminants. It serves the same purpose over any painted surface. Visit any indoor basketball floor and you will quickly become a believer. Lines, logos and all sorts graphics are being painted on these floors with this very same product line.

Industrial floor paint jobs begin just as any other painting project. The surface to receive paint should be clean, dry, dust-free and as smooth as possible. Large depressions and cracks in wood flooring need to be filled with a product that dries good and hard. We do not recommend the use of caulk or lightweight spackling compounds as floor repair materials. There are a number of excellent plastic-type wood fillers that dry exceptionally hard. Certain floor leveling compounds that are mixed with water can be very hard when dry.

Steel and wood floors should be primed with the right primer products prior to the application of an industrial floor paint, however, 1-Part Epoxy and Urethane Reinforced Alkyd are self priming with two coats on concrete and porous substrates.  Concrete floors may require an epoxy primer such as Ever-Last Epoxy primer (TS-6390). Solvent based Industrial floor paints work best for painting manufacturing and industrial applications because chemical resistance and hardness is superior to water-based systems. They also tend to cure and harden faster.

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14. COMMERCIAL FLOOR PAINT

It is not only possible to paint floors but with today’s new generation commercial floor paint products your job may actually end up looking than you expect. There is no real magic in painting a floor. You simply have to follow a few simple steps and use the right products to achieve attractive, durable, long-lasting results.

Just about any flooring surface that is in good shape can be painted. Concrete, wood, ceramic tile, vinyl, masonry, tile, etc. can all be painted with ease. The only surface that may have problems would be an older basement concrete floor that is below grade, that could have hydrostatic pressure, or one that is in contact with a very wet soil. Water that seeps into concrete can sometimes cause a painted finish to peel, if not properly applied or inferior products have been used. Many modern concrete floors installed since the 1970's have a vapor barrier under the slab preventing moisture or water vapor out allowing the paint to adhere or bond properly to the concrete. Top Secret Coatings offers a variety of quality industrial quality and commercial floor paint products that the D-I-Y’er can easily apply at home.

Most people take for granted the hardness and durability of clear urethanes. Quality products such as Hard-Shell Urethane and Aquathane have been formulated for use in industrial applications and professional sports arenas so they are definitely acceptable for at home use. For example customers using Top secret products on hardwood floors coated with TS 6990 Aquathane water-based urethane are achieving excellent results with these products. Home center brands can begin to look dingy and dull in a very short amount of time.

Thin coats of smooth Aquathane can protect hardwood floors from dirt and other contaminants. It serves the same purpose over any painted surface. Visit any indoor basketball floor and you will quickly become a believer. Lines, logos and all sorts of things are painted on these floors with this very same product line. The paint looks great because of the invisible layers of urethane that are on top of the paint.

Commercial floor paint jobs begin just as any other painting project. The surface to receive paint should be clean, dry, dust-free and as smooth as possible. Large depressions and cracks in wood flooring need to be filled with a product that dries good and hard. We do not recommend the use of caulk or lightweight spackling compounds as floor repair materials. There are a number of excellent plastic-type wood fillers that dry exceptionally hard. Certain floor leveling compounds that are mixed with water can be very hard when dry. You will want to test these materials by walking on them after they dry.

Bare wood floors should be primed with the right primer products prior to the application of a commercial floor paint. These products work well to hide the wood grain that otherwise might show through the finish paint. Hardwood floors that have a varnish or urethane finish must be sanded before a primer is applied. Concrete floors may require an epoxy primer such as Ever-Last Epoxy Primer.

Solvent based commercial floor paints work best for floor painting. These resins typically adhere better than water-based products and are harder when fully cured. They also tend to cure and harden faster.

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15. CONCRETE COATINGS

Concrete, it’s practical, sturdy and has been used in the construction of buildings since the early Roman times. However, without a decorative or protective coating most concrete patios, driveways, walkways and garage floors are unattractive. In fact, more than likely, they’re stained, drab, dull, possibly, even ugly.

Today many homeowners and do-it-yourselfers are discovering, through the use of Top Secret Coatings concrete coatings, those gray, cold outdoor slabs can take on a unique, stylish look that not only reflects homeowners particular tastes but are non skid, add color and texture to a new or older home.

A porch or patio can be one of the most useful exterior areas of your home if covered with an attractive concrete coating, cleared of all excess junk and with a little thought given to landscaping the area. Unfortunately these spaces are all too often covered with bland concrete which as well as looking rather dull and dreary, may have developed cracks or become stained with moss, grease, oil etc over time. Restoring such areas to a place you would be proud to use for entertaining, outdoor dining or just relaxing may seem like a mighty big job. If the concrete is badly cracked and the surface uneven, generally there is no other choice than to rip it up and re-lay it. Here are a few thoughts to consider before moving forward with your plans to apply concrete coatings.

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1. If your floor is inside the house, do a little checking before you decide to coat your floor. Is the concrete damp? Are there any ponding water? (If so, then you have a larger problem than an ugly floor!) Let the concrete dry thoroughly before painting (this may take a while during the wet seasons!)
 

2. Thoroughly clean the concrete with TS-695 Etching Cleaner. If there is any grease on the floor you will want to remove it before painting or the paint may not adhere. To remove grease, put down cat litter to absorb the majority of oil, then scrub again with TS-695 Etching Cleaner. Rinse well and wait until the floor is thoroughly dry.
 

3. Sand off any loose or peeling paint or other residue with a sander or 40 grit sandpaper. Vacuum or sweep up the residue. Then go over the floor with a tack cloth (a sticky cheesecloth available at any hardware or home improvement store).
 

4. Use a paintable cement filler to repair any cracks and holes and allow it to dry completely before moving forward.
 

5. Now to begin the painting process. You will want to brush the edges and roll the rest of the floor surface. Let each coat dry between 12 and 24 hours before recoating. Repeat the process with the second or third coats as directed.  

 

Now you have applied Top Secret quality concrete coatings that are beautiful, colorful and durable!

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16. EPOXY COATINGS

Traditional epoxy coatings are widely used because of their outstanding chemical resistance, durability, low porosity and strong bond strength. More advanced protective coatings are available, however, traditional two part epoxies are an entrenched part of the coatings industry and here to stay.

Traditional epoxies consist of a ‘base' and a ‘curing' agent. The two components are typically mixed in a 1:1ratio. A chemical reaction occurs between the two parts generating heat thus hardening the mixture into an inert, hard ‘plastic'.

The knock on these epoxy coatings are that typically, they yellow, chalk and can loose their gloss in direct sunlight (UV). The yellowing can be a real problem. For pigmented epoxy coatings you may want to select colors that are dark or contain a lot of yellow (such as green). Even clear epoxies will yellow and cloud up. Often epoxy coatings are top coated with latex or urethanes that will retain their color and attractive gloss. This is particularly true if color coding or matching company colors is important.

For these very reasons Top Secret Coatings has made a major investment in a completely new approach to epoxy with its 1-Part Epoxy. This unique product is remarkable because it is catalyzed by oxygen rather than chemically making it the latest in coatings technology. It is a one of a kind, super-premium blend of four hybrid resins that out performs traditional two part epoxy. No other epoxy coating utilizes this kind of advanced coatings technology. Industry veterans recognize this product as being something very special.

Brush it on and watch the marks disappear before your eyes! It self levels like a dream. Now for the first time you can brush or roll your job and it will look sprayed! 1-Part Epoxy creates a high-gloss waterproof film that remains both hard and flexible at the same time! It adheres to almost anything, inhibits rust, waterproofs and is resistant to chemicals, spilled fuel and acids, even brake fluid! It is impact resistant to 500 PSI, heat resistant to 350 + degrees, color-fast, UV resistant, non-chalking and it resists cracking, chipping and peeling. It covers three times the area of typical paint because its maximum dry film thickness is only two mils. That’s half the thickness of a sheet of paper! It out performs traditional epoxy in most categories.

It offers excellent performance in Marine, Industrial, Floor, Roof, Automotive, Commercial, Farm and at Home applications. A lead-free child safe formula.

PRODUCT FEATURES

• Outstanding Resistance To Chemicals, Fuel & Salt
• Self Levels Like a Dream
• High Heat Resistance
• Superior Adhesion, One Coat Coverage
• Easy To Clean, No More Waxing Or Buffing
• Excellent Hardness, Durability
• Non-yellowing, UV Stable, Colorfast
• Superior Gloss Retention, No Clear Coat Required
• Prevents Hot Tire Pickup On Floors
• Excellent Abrasion & Mar Resistance
• Waterproofs, Seals, Protects, Inhibits Rust
• Easy Application, Low Maintenance
• High Solid, Low VOC, Low Odor Formula
• Meets UDSA, FDA & EPA Standards
• Resists Chipping, Cracking & Peeling
• Allows Low Temperature Application
• Economical To Use
• Self Priming In Many Applications
• Acceptable for Indoor/Outdoor Use
• Resistant To Bacteria, Mold, Mildew & Fungus
• Wide Variety Of Application Possibilities

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17. EPOXY FLOOR COATINGS

Previously painted floors must be evaluated, prior to application of epoxy floor coatings. If the old floor paint comes loose, the new epoxy floor coatings system will of course come up with it. Before moving forward you will want to examine the old painted surface carefully for adhesion and structural stability prior to application of a high performance epoxy floor system. Remember, a chain is only as strong as its weakest link.

If the old paint is firm and sound then it should be sanded or power washed removing any loose or peeling old material. If the old coatings identity is unknown, apply a small sample of the Top Secret Coatings Product you have chosen to test for compatibility and adhesion. 

New concrete should be cured at least one month. Bare Concrete Floors must be cleaned and etched prior to coating with an etching cleaner such as TS-695 Etching Cleaner. Wet the floor first then flood it with the mixture and allow approximately five to ten minutes contact time. Scrub with a stiff broom or brush and then rinse. Heavy grease and oil spots must be treated with an unreduced Etching Cleaner solution to eliminate contaminates. Repeat as many times as necessary. Safety comes first so always wear protective glasses, and rubber gloves, when working with Etching Cleaner.

Concrete requires a thoroughly dry surface. You can test to see if your floor is dry enough, by placing the rubber car mat from your car on the floor, and allowing it to stand overnight. If the area under the mat is visibly darkened, or condensation has formed under the mat, you should allow for additional dry time.

Many Top Secret epoxy floor coatings require mixing or an addition of accelerator/hardener prior to application. Mixing should be done with a drill attachment or “jiffy-type” mixer at low-medium speeds (<750 rpm). Mix the components together until uniform in color and consistency. It is best not to mix by hand, or with a stick. Do not mix less than the prescribed amount of any ingredient or add solvent to the mix.

Normally new or uncoated concrete floors are primed with a primer coat of some kind. This primer coat may be a primer product or an initial coat of product that serves as a primer coat. An example would be 1-Part Epoxy which is self priming in two coats. After reading all instructions carefully apply this primer application with a short nap adhesive cover.

Apply your color coat of epoxy floor coatings when the primer is dry to the touch. If it is just slightly tacky that is acceptable too but it is best if done before 48 hours. For best results apply all epoxy floor coatings between 50 F and 90F. If these recoat times are exceeded then lightly sand the primer prior to applying the finish coat.

If a second layer of top coat or you are applying a clear coat, recoat when dry enough to walk on, but before 48 hours. If more time has elapsed since the first application of your top coat then you will want to sand lightly before recoating.

NOTE: Never apply epoxy floor coatings in the direct sunlight. Pot life varies with temperature. Depending on temperature you have two hours to use most accelerated or catalyzed Top Secret epoxy floor coatings. Do not mix less than the prescribed amount of any ingredient or add solvent to the mix unless directed to do so. While the coating is wet broadcast Super Fleck acrylic chips onto the coating, by dropping the chips head high as you proceed. Keep vehicles off the newly painted surface for a minimum of 7 days to allow the product to cure fully.